Rosemount 1500XA Gas Chromatograph Manuals & Guides

Rosemount™ 1500XA

Process Gas Chromatograph

Reference Manual

2-3-9000-762, Rev C

May 2022

Notice

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IMPLIED, REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY. WE RESERVE THE RIGHT
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Warranty

LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided

1.
herein, Emerson (“Seller”) warrants that the firmware will execute the programming instructions provided by Seller and
that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under
normal use and care until the expiration of the applicable warranty period. Goods are warranted for twelve (12) months
from the date of initial installation or eighteen (18) months from the date of shipment by Seller, whichever period expires
first. Consumables and Services are warranted for a period of 90 days from the date of shipment or completion of the
Services. Products purchased by Seller from a third party for resale to Buyer (“Resale Products”) shall carry only the
warranty extended by the original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond
making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If Buyer
discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period, Seller shall, at
its option, promptly correct any errors that are found by Seller in the firmware or Services, or repair or replace F.O.B. point
of manufacture that portion of the Goods or firmware found by Seller to be defective, or refund the purchase price of the
defective portion of the Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normal
wear and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse, improper installation,
modification, repair, storage or handling, or any other cause not the fault of Seller are not covered by this limited
warranty, and shall be at Buyer's expense. Seller shall not be obligated to pay any costs or charges incurred by Buyer or any
other party except as may be agreed upon in writing in advance by an authorized Seller representative. All costs of
dismantling, reinstallation and freight, and the time and expenses of Seller's personnel for site travel and diagnosis under
this warranty clause shall be borne by Buyer unless accepted in writing by Seller. Goods repaired and parts replaced during
the warranty period shall be in warranty for the remainder of the original warranty period or ninety (90) days, whichever is
longer. This limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an
authorized representative of Seller. Except as otherwise expressly provided in the Agreement, THERE ARE NO
REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR
PARTICULAR PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. It is understood
that corrosion or erosion of materials is not covered by our guarantee.

LIMITATION OF REMEDY AND LIABILITY: SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN

2.
PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY HEREUNDER SHALL BE LIMITED TO
REPAIR, CORRECTION, REPLACEMENT, OR REFUND OF PURCHASE PRICE UNDER THE LIMITED WARRANTY CLAUSE IN
SECTION 1 HEREIN. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN
CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT, OR OTHERWISE), SHALL SELLER'S LIABILITY TO
BUYER AND/OR ITS CUSTOMERS EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES
PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL
SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE
DAMAGES. THE TERM “CONSEQUENTIAL DAMAGES” SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED
PROFITS, LOSS OF USE, LOSS OF REVENUE, AND COST OF CAPITAL.

Certifications and safety information

Your installation must comply with all certifications and safety instructions.

Rosemount 1500XA Gas Chromatograph system

Rosemount 1500XA Gas Chromatographs are designed to meet the specifications for Class 1, Division 2, Groups B, C, and D area
classification using a Z-purge system. An optional Nationally Recognized Testing Laboratory (NRTL) third party certification is

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available when ordering. This option ensures that an NRTL organization has reviewed, tested, and certified the Rosemount
1500XA Gas Chromatograph to the applicable product safety test standards.

NOTICE

The Rosemount 1500XA is field certified product by an National Recognized Testing Lab for both US and Canadian standards.
Internal components or related assemblies may contain their own individual product certifications.

Rosemount 1500XA Gas Chromatograph system optional certification

Class 1, Division 2, Groups B, C, and D

Rosemount 1500XA Gas Chromatograph intrinsically safe back plane

Class I, Division 2 Groups B, C, and D

Associated equipment for: Class I, Division 1, Groups B, C, and D

Ex nA [ic IIB + H2 Gc] IIB + H2 Gc

Zone 2 AEx nA [ic IIB + H2 Gc] IIB+ H2 Gc

Rosemount 1500XAGas Chromatograph explosion-proof flame ionization detector (FID)

Class I, Division 1 Groups B, C, and D

Ex db IIB+H2 Gb

Class I, Zone 1, AEx db IIB+H2 Gb

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Reference Manual Contents

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Contents

Chapter 1 About Rosemount 1500XA Gas Chromatographs........................................................7

1.1 Overview..................................................................................................................................... 7

1.2 Software description..................................................................................................................10

1.3 Embedded gas chromatograph (GC) firmware...........................................................................10

1.4 Rosemount MON2020...............................................................................................................10

1.5 Equipment description.............................................................................................................. 12

Chapter 2 Getting started.........................................................................................................19

2.1 Site selection............................................................................................................................. 19

2.2 Unpack the gas chromatograph (GC).........................................................................................19

2.3 Necessary tools and components.............................................................................................. 20

2.4 Optional tools and components.................................................................................................21

Chapter 3 Installation and start-up .......................................................................................... 23

3.1 Install a gas chromatograph (GC) in hazardous environments....................................................23

3.2 Gas chromatograph wiring........................................................................................................ 24

3.3 Installing the analyzer................................................................................................................ 27

3.4 Leak checking and purging for first calibration...........................................................................68

3.5 Start up the system....................................................................................................................71

3.6 Start a 2-point calibration.......................................................................................................... 72

Chapter 4 Maintaining and troubleshooting the gas chromatograph........................................75

4.1 Maintenance and repairs in hazardous environments................................................................ 75

4.2 Troubleshooting and repair....................................................................................................... 75

4.3 Routine maintenance................................................................................................................ 76

4.4 Access to gas chromatograph (GC) components....................................................................... 78

4.5 Precautions for handling printed circuit (PC) assemblies............................................................ 78

4.6 Troubleshooting........................................................................................................................ 79

4.7 Checking the GC for leaks.......................................................................................................... 99

4.8 Repairing and maintaining the valves.........................................................................................99

4.9 Repairing and maintaining the detectors................................................................................. 102

4.10 Replacing the methanator..................................................................................................... 109

4.11 Measure vent flow................................................................................................................. 110

4.12 Access electrical components................................................................................................111

4.13 Analog inputs and outputs.....................................................................................................113

4.14 Upgrading the embedded software....................................................................................... 113

Appendix A Theory of operation................................................................................................115

A.1 Thermal conductivity detector (TCD)...................................................................................... 115

A.2 Flame ionization detector (FID)............................................................................................... 117

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A.3 Data acquisition...................................................................................................................... 117

A.4 Peak detection........................................................................................................................ 118

A.5 Basic analysis computations.................................................................................................... 119

A.6 Functional description............................................................................................................. 121

Appendix B Specifications......................................................................................................... 125

Appendix C Local operator interface (LOI)................................................................................. 127

C.1 Local operator interface (LOI) for displaying and entering data................................................ 127

C.2 Local operator interface (LOI).................................................................................................. 128

C.3 Using the local operator interface (LOI)................................................................................... 129

C.4 Navigate and interact with the screen......................................................................................140

C.5 Local operator interface (LOI) screens......................................................................................148

C.6 Troubleshoot a blank local operator interface (LOI) display screen...........................................178

Appendix D Carrier gas installation and maintenance................................................................179

D.1 Carrier gas...............................................................................................................................179

D.2 Install manifold and purge line................................................................................................ 180

D.3 Replace carrier cylinder........................................................................................................... 181

Appendix E Recommended spare parts.....................................................................................183

Appendix F Shipping and long-term storage recommendations................................................185

Appendix G Pre-defined Modbus® map files..............................................................................187

Appendix H Engineering drawings............................................................................................ 189

H.1 List of engineering drawings....................................................................................................189

Appendix I Glossary................................................................................................................. 191

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1 About Rosemount 1500XA Gas

Chromatographs

1.1 Overview

The Rosemount 1500XA is a high-speed gas chromatograph (GC) that is factory
engineered to meet specific field application requirements based on stream composition
and the anticipated concentration of the components of interest.

This GC was fully inspected and tested before it left the factory. Program parameters were
installed and documented in the GC Config Report furnished with the USB stick shipped in
your documentation package.

Components

The GC typically consists of two major components, the analyzer assembly and the sample
conditioning system (SCS).

Analyzer assembly (XA series)

The assembly includes:

□ Columns

□ Detectors

□ Preamplifier

□ Valves

□ Solenoids

□ Analyzer, which includes:

— Electronics and ports for signal processing

— Pressure control

— Instrument control

— Data storage

— Personal computer (PC) interface

— Telecommunications

Sample conditioning system

The SCS is located between the process stream and the analyzer sample inlet, usually
mounted on the lower portion of the analyzer stand.

Optionally, we can configure the SCS with Genie® bypass filters, liquid shut-off valves, and
optional solenoids for stream switching, all of which can be enclosed in an electric (heat
tape design) oven.

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The standard configuration SCS includes:

• Mounting plate

• Block (or shutoff) valves

• Filters

In its standard configuration, the analyzer can handle multiple streams.

Operation

Although the GC can be operated from the local operator interface (LOI), it is designed to
be run primarily from PC running Rosemount MON2020 software. The PC provides you
with the greatest capability, ease of use, and configuration flexibility. One PC running
Rosemount MON2020 can connect with multiple gas chromatographs over a local area
network. The GC’s Ethernet capability makes it possible to interact with the GC even if it is
located in a hazardous area. You can use a PC to display chromatograms and reports,
which can then be stored as files on the PC’s hard drive.

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Typical installation

Figure 1-1: System overview

A. ¼-in. connector carrier in

B. ¼-in. connector valve actuation gas
C. Electronics enclosure
D. Air-bath oven

E. ¼-in. air regulator in

F. ¾-in. customer connection
G. LOI display
H. ¼-in. air regulator

I. Z-Purge pressure regulator
J. ¾-in. customer connection

K. ¾-in. customer connection

L. Mechanical pressure regulator panel

M. Cyclops Z-Purge indicator

Documentation

This Manual provides information on operating the GC.

For software operation instructions, see the Rosemount MON2020 Software for Gas

Chromatographs Reference Manual (PN 2-3-9000-745). The reference and software

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manuals are included on the Rosemount MON2020 software USB stick that ships with the
GC. Alternatively, you can download them from Emerson.com.

Related information

Local operator interface (LOI)
Rosemount MON2020

1.2 Software description

The gas chromatograph (GC) uses two distinct types of software. This enables total
flexibility in defining the calculation sequence, report content, format, type and amount of
data for viewing, control, and/or transmission to another computer or controller
assembly.

The two types are:

• Embedded GC firmware

• Rosemount MON2020 software

The application configuration is tailored to the customer’s process and shipped on a USB
stick. The hardware and software are tested together as a unit before the equipment
leaves the factory.

Rosemount MON2020 communicates with the GC and can be used to initiate site system
setup, such as operational parameters, application modifications, and maintenance.

1.3 Embedded gas chromatograph (GC) firmware

The GC’s embedded firmware supervises operation of the Rosemount 1500XA through its
internal microprocessor-based controller.

All direct hardware interface is via this control software. It consists of a multitasking
program that controls separate tasks in system operation, as well as hardware self-testing,
user application downloading, start-up, and communication. After configuration, the GC
can operate as a stand-alone unit.

1.4 Rosemount MON2020

Emerson has designed the Rosemount 1500XA Gas Chromatograph (GC) to operate
unattended. If adjustments are needed, Emerson's proprietary desktop software,
Rosemount MON2020, allows complete control of the GC either locally or remotely.

From the software, you can:

• Start or stop analysis, calibration, or validation cycles.

• Configure, ignite, and check the status of the flame photometric detector (FPD) or the

flame ionization detector (FID) flames.

• Generate and save current and historical analysis and calibration reports.

• Review and modify analytical settings.

• Upload and display multiple chromatograms for comparison.

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• Upload and trend any of the measured results.

• Export data to text, HTML, or Microsoft® Excel™ for use in third party applications.

• Check on original calibration against the last calibration.

• Perform GC operation checks and modifications simultaneously.

• Upload and view manuals and drawings stored in the gas chromatograph.

Rosemount MON2020 is a Windows®-based software program that makes analyzer
configuration, maintenance, and data collection easy. With intuitive drop-down menus
and fill-in-the-blank tables, even new users can quickly navigate through the software.

Figure 1-2: Rosemount MON2020 interface

A. Simple drop-down menus

B. Connect to any GC with a mouse click
C. Full featured chromatogram display
D. Response Factor fidelity chart

E. Fully detailed Timed Events table

F. Automatic listing of measured components
G. Quickly add chromatograms to overlay
H. Save chromatograms to hard drive

With its abilities to communicate with your enterprise network and export to numerous
file types, Rosemount MON2020 is a powerful tool that ensures operators, engineers,
maintenance personnel, and management have access to critical data, such as current and
archived chromatograms, alarm history, event logs, and maintenance logs.

The software's chromatogram viewer allows you to view and compare both live and
archived chromatograms simultaneously. Despite its small size, the chromatogram file
includes analysis and calculation results, integration and valve time settings, retention
time settings, and raw peak data.

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The trend viewer makes it easy to trend multiple variables on a single chart. To help
diagnose process or analysis issues, you can select single or multiple points on the trend
viewer; the chromatograms associated with these points will open in the chromatogram
viewer. You can save the trend files or export them as text, CSV, or Excel files.

Rosemount MON2020 can connect to a Rosemount GC via Ethernet directly or over your
local or wide area network. The software is equipped with multi-level username and
password security settings to limit and control access to the GC and provide levels of
access authority ranging from read-only access to full control of the GC and its data.

1.5 Equipment description

The Rosemount 1500XA Gas Chromatograph combines the proven analytical components
of the Rosemount 700XA Gas Chromatograph with the larger oven capacity and flexibility
of a traditional air-bath oven design.

1.5.1

Electronics enclosure

The Rosemount 1500XA electronics enclosure contains:

• Card cage assembly

• Local operator interface (LOI)

• Backplane

• AC/DC power supply

• Circuit breaker

• Solenoid valves

• Electronic pressure controllers (EPCs)

• Z-purge controller

Local operator interface (LOI)

The LOI gives you in-depth control over the functions of the gas chromatograph (GC).

The LOI has a high resolution color display that is touch key activated and allows you to
operate the GC without a computer.

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Figure 1-3: LOI

The LOI includes the following features:

• Color LCD display with VGA (640 x 480 pixels) resolution

• ASCII text and graphics modes

• Adjustable auto-backlighting

• Eight infrared-activated touch screen keys that eliminate the requirement for a

magnetic pen

• Complete GC status, control, and diagnostics, including full chromatogram display

Pressure switch

The pressure switch activates when the carrier pressure falls below a predetermined set
point. When activated, the switch triggers a general alarm that displays on the local
operator interface (LOI) and in Rosemount MON2020.

Mechanical pressure regulators

The mechanical pressure regulators and gauges are used to set and monitor the pressure
of the carrier gas flow through the gas chromatograph's columns, as well as the pressure
of the flame ionization detector (FID) or flame photometric detector (FPD) air and fuel
(H2), if installed.

The regulators and gauges are typically located on the top or side of the electronics
enclosure.

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Figure 1-4: Regulators and Gauges

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Electronic pressure controller (EPC) interface board

The XA EPC interface board is an electronic circuit board designed to control EPCs.

Figure 1-5: EPC board

A. EPC boards

B. LEDs
C. J21: Power connector
D. F1: 5 amp fuse

E. Switch 1: Controller area network (CAN) communication

F. J2: JTAG
G. J1: USB debug port
H. Switch 2: Not applicable (only used for gas chromatographs with multiple EPC boards)

The EPC board comes with an on-board microprocessor which allows it to communicate to
other processors over a controller area network (CAN). You can use the JTAG interface to
load firmware onto the board. The EPC board also includes a mini USB interface, which can
be used for debugging internal board operations.

The EPC board is powered at 24 Volts through a four pin connector (J21), which also
contains the CAN differential lines that allow for communication to the gas
chromatograph's (GC's) main central processing unit (CPU) board. A 5 amp fuse ensures
power cut-off in case of an electrical malfunction. There are also over-voltage and under­voltage cut-off circuits to ensure that the board can only operate between 18 and 30
Volts.

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Switch 1 enables the termination for CAN communication. Set both switches on the switch
1 device to ON. Always set switch 2 on the EPC board to 0. Switch 2 is designed to allow for
multiple EPC boards to use the CAN interface. Since there is only one EPC board in a
Rosemount 1500XA, always keep this switch set to 0.

The EPC board contains connections for up to 12 EPCs (J11 to J19), which the operator can
control simultaneously to regulate pressure and give feedback on EPC device details. Each
EPC channel is designed to power the EPC device at 24 V and communicate with it over a
standard RS-232 serial interface. There are 12 LEDs placed under the EPC connectors,
which show the communication state of each connected EPC. Upon start-up, the EPC
board attempts to communicate with each channel. If the board finds an EPC on the
channel, the corresponding green LED lights up, showing that the communication
attempt was successful. If an EPC is present, but the board can't communicate with it, the
corresponding red LED lights up. If there is no EPC connected to the channel, the EPC LED
will not light up.

1.5.2

Air-bath oven

The air-bath oven uses a conventional instrument air heater design for maximum
analytical flexibility.

The oven has capacity for up to eight chromatograph valves and four detectors. It also has
the capacity for liquid sample injector valves (LSIVs) for heavier samples.

The oven can operate at temperatures up to 248 °F (120 °C) as the application dictates.

The air-bath oven contains the valves, the columns, the detectors, and the stream
switching system.

Note

The analyzer can have a maximum of two flame detectors (flame ionization detector and
flame photometric detector) and/or four thermal conductivity detectors (TCDs). The oven
cannot contain two flame photometric detectors (FPDs), but it can contain two flame
ionization detectors (FIDs).

A more detailed component list for the oven compartment includes the following:

Table 1-1: Air-bath oven components

Component Description

Valves Up to 8 XA pneumatically actuated valves.

Column module Columns are either capillary or micro-packed.

TCDs Supports a maximum of 4 TCDs.

Temperature switch Switch for the heating element. The switch turns off its heating

element if the heating element reaches 257 °F (160 °C).

FID The optional FID can be used in place of a TCD to detect trace

levels of compounds.

Micro flame photometric detector (µFPD) The optional µFPD uses a photo multiplier tube (PMT) to collect

the light emitted when the sample is burned in the presence of
air and hydrogen. The sample of gas to be measured is also
injected into the burner.

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Table 1-1: Air-bath oven components (continued)

Component Description

LSIV The optional LSIV converts a liquid sample into a gas sample for

gas chromatograph (GC) analysis.

Oven heater

1.5.3 Sample system

A well designed, properly adjusted sampling system is essential for optimum performance
of any gas chromatograph (GC). If a good sample is not obtained for analysis, the system is
compromised.

The purpose of the sample handling system is to transfer a conditioned fluid sample that is
compatible with gas chromatography requirements.

The sample conditioning system (SCS) is located between the process stream and the
analyzer, and is usually mounted beneath the air-bath oven. It serves these purposes:

• Extracts final sample from the fast loop.

• Performs final filtration.

• Performs stream switching for a multi-stream analyzer.

• Adjusts the final pressure, temperature, and flow on the selected sample flowing to the

sample valve.

When selecting and installing a sampling system, consider the following:

• Sample point

• Sample volume and flow rate

• Sample conditioning

• Contamination precautions

• Valving

• Calibration gas

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2 Getting started

2.1 Site selection

The site selected for the gas chromatograph (GC) is important for measurement accuracy.

Install the GC as close as possible to the sample system but allow for adequate access
space for maintenance tasks and adjustments. Allow a minimum of 3 ft. (0.9 m) in front of
the GC for operator access.

Ensure that exposure to radio frequency (RF) interference is minimal.

WARNING

HAZARDOUS AREA EXPLOSION HAZARD

Failure to follow this warning may result in injury or death to personnel.

Do not use a personal computer (PC) or printer in a hazardous area. Serial and Ethernet
communication links are provided to connect the analyzer to the PC and to other
computers and printers in a safe area.

WARNING

VENTILATION

If you plan to place the GC in a sealed shelter, always vent the GC to atmosphere with ¼-in.
tubing or larger. This will prevent the build-up of gases.

2.2 Unpack the gas chromatograph (GC)

Unpack and inspect the Rosemount 1500XA upon receipt.

Procedure

1. Unpack the equipment.

a) Remove the GC from the shipping crate.

b) Remove the USB memory stick containing the software, applications, Quick

Start Guide, and manuals.

Note

The Rosemount MON2020 version number is located on the back of the USB
card.

2. Retain the shipping information.

3. Inspect all parts and assemblies for possible shipping damage.

4. If any parts or assemblies appear to have been damaged in shipment, first file a

claim with the carrier.

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5. Next, complete a full report describing the nature and extent of the damage and

forward this report immediately to your Emerson Customer Care representative.
Include the GC's model number in the report.
Emerson will provide disposition instructions as soon as possible. If you have any

questions regarding the claim process, contact your Emerson Customer Care
representative for assistance.

6. Only proceed to install and start up the GC if all required materials are on hand and

free from obvious defects.

2.3 Necessary tools and components

You will need the following tools and components to install the analyzer.

• Chromatographic grade carrier gas: 99.995% pure with less than 5 ppm water and 0.5

ppm hydrocarbons. Possible carriers gases (application dependent) include:

— Helium

— Nitrogen

— Argon

— Hydrogen

• High pressure dual-stage regulator for the carrier gas cylinder: high side up to

3,000 psig (206.84 barg); low side capable of controlling pressure up to 150 psig
(10.34 barg).

• Calibration standard gas with correct number of components and concentrations.

• Dual-stage regulator for the calibration gas cylinder, low pressure side capable of

controlling pressure up to 30 psig (2.07 barg).

• Sample probe (fixture for procuring the stream, or sample gas for chromatographic

analysis).

• Stainless steel tubing:

— ⅛ in. for connecting calibration standard to analyzer.

— ⅛ in. for connecting stream gas to the analyzer.

— ¼ in. for connecting carrier to the analyzer.

• Sulfur-inert coated , stainless steel tubing for H2S applications.

• Miscellaneous Swagelok® tube fittings, tubing benders and tubing cutter.

• 14 AWG (18 MWG) or larger electrical wiring and conduit to provide

115 or 220 volts AC, single phase, 50 to 60 Hertz (Hz), from an appropriate circuit
breaker and power disconnect switch.

• Digital volt-ohm meter with probe-type leads.

• A flow measuring device.

• Phillips antistatic screwdriver.

• 7/32-in. Allen wrench.

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• Channel lock wrench

Related information

Wiring precautions

2.4 Optional tools and components

WARNING

EXPLOSION HAZARD

Electrostatic discharges may cause an explosion. Serial port and Ethernet are provided to
connect the gas chromatograph (GC) to the personal computer (PC) and to connect to
other computers and printers in a safe area. Failure to follow this warning may result in
injury or death to personnel.

Do not use a PC in a hazardous area.

Supporting tools and components include:

• A Windows™-based PC and either a direct or remote communications connection to

interface with the Rosemount 1500XA. See the Rosemount MON2020 Software for Gas

Chromatographs Reference Manual for more information on specific PC requirements.

• The Rosemount 1500XA has a factory-wired Ethernet port on the back plane.

• Modbus® communications are optional

Related information

Connect directly to a personal computer (PC) using the gas chromatograph's (GC’s)
Ethernet1 port

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3 Installation and start-up

Note

Because the Rosemount 1500XA is available in different configurations, it is possible that
not all of the instructions in this section apply to your particular gas chromatograph (GC).
In most cases, however, to install and set up a Rosemount 1500XA, Emerson recommends
that you follow the instructions in the same order as they are presented in this manual.

3.1 Install a gas chromatograph (GC) in hazardous environments

WARNING

Follow these precautions if installing or operating the GC in a hazardous area.

Procedure

1. Do not operate a personal computer (PC) in a hazardous area. To interface with a
GC in a hazardous area, use a PC that is remotely connected to the GC and that is
located in a nonhazardous area.

2. Ensure that field connections to the analyzer and the GC are appropriately certified
and made through purged conduit or flameproof glands.

WARNING

Failure to observe all regulations when installing purged GC units may result in
noncompliance, equipment damage, or personal injury.

Observe all applicable regulations when installing purged GC units.

The purged analyzer housing is designed for use in locations where fire and
explosion hazards may exist, specifically areas that are classified by the National Fire
Protection Association (NFPA) as Class I, Division 2, Group B, C, and D. However,
other regulations do apply. Consult the authority having jurisdiction or appropriate
site policies and procedures regarding wiring and installation practices.

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3.2 Gas chromatograph wiring

3.2.1 Wiring precautions

• All wiring, as well as circuit breaker or power disconnect switch locations, must

conform to the CEC or NEC; all local, state, or other jurisdictions; and company
standards and practices.

• Provide single-phase, three-wire power at 115 or 220 Vac, 50-60 Hz.

NOTICE

If you do not have a single phase, three-wire AC power source, you must purchase an
isolation transformer.

• Locate a power shut-off or disconnect switch in a safe area.

• Provide the gas chromatograph (GC) and any optionally installed devices with one 20-

amp circuit breaker for protection.

3.2.2

NOTICE

15 amps is the maximum current for 14 American Wire Gauge (AWG).

• Use multi-stranded copper conductor wire according to the following

recommendations:

— For power feed distances up to 250 ft (76 m), use 14 AWG (18 metric wire gauge

[MWG]), stranded.

— For power feed distances 250 ft (76 m) to 500 ft (152 m), use 12 AWG (25 MWG),

stranded.

— For power feed distances 500 ft (152 m) to 1,000 ft (305 m), use 10 AWG (30

MWG), stranded.

Signal wiring

Follow these general precautions for field wiring digital and analog input/output (I/O)
lines:

• For shielded signal conducting cables, shield-drain wires must not be more than two

American Wire Gauge (AWG) sizes smaller than the conductors for the cable. Shielding
is grounded at only one end.

• Metal conduit or cable (according to local code) used for process signal wiring must be

grounded at conduit support points, because intermittent grounding helps prevent the
induction of magnetic loops between the conduit and cable shielding.

• A single-point ground must be connected to a copper-clad, 10 ft (3.05 m) long, 0.75 in

(19.0 mm) diameter steel rod, which is buried, full-length, vertically into the soil as
close to the equipment as is practical.

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NOTICE

The grounding rod is not furnished.

• Resistance between the copper-clad steel ground rod and the earth ground must not

exceed 25 Ohms.

• On ATEX-certified units, the external ground lug must be connected to the customer’s

protective ground system via 9 AWG (6 mm2) ground wire. After the connection is
made, apply a non-acidic grease to the surface of the external ground lug to prevent
corrosion.

• The equipment-grounding conductors used between the gas chromatograph (GC) and

the copper-clad steel ground rod must be sized according to your local regulations; the
following specifications apply in the US.

• All interior enclosure equipment-grounding conductors must be protected by metal

conduit.

• External equipment that is connected to the GC should be powered via isolation

transformers to minimize the ground loops caused by the internally shared safety and
chassis grounds.

• All process signal wiring should be of a single, continuous length between field devices

and the GC. If, however, the length of the conduit runs require that multiple wiring
pulls be made, the individual conductors must be interconnected with suitable
terminal blocks.

• Use suitable lubrication for wire pulls in conduit to prevent wire stress.

• Use separate conduits for AC voltage and DC voltage circuits.

• Do not place digital or analog I/O lines in the same conduit as AC power circuits.

• Use only shielded cable for digital I/O line connections.
— Ground the shield at only one end.

— Shield-drain wires must not be more than two American Wire Gauge (AWG) sizes

smaller than the conductors for the cable.

• When inductive loads (relay coils) are driven by digital output lines, the inductive

transients must be diode-clamped directly at the coil.

• Any auxiliary equipment wired to the GC must have its signal common isolated from

earth/chassis ground.

NOTICE

Signal interference
If you don't follow this precaution, the data and control signals to and from the GC could
be adversely affected.

Do not place any loop of extra cable left for service purposes inside the GC purged housing
near the conduit entry for AC power.

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3.2.3 Electrical conduit installation precautions

• Conduit cutoffs must be cut at a 90-degree angle. Cut conduits with a cold cutting tool,

hacksaw, or by some other approved means that does not deform the conduit ends or
leave sharp edges.

• Coat all conduit fitting-threads, including factory-cut threads, with a metal-bearing

conducting grease prior to assembly.

• Temporarily cap the ends of all conduit runs immediately after installation to prevent

accumulation of water, dirt, or other contaminants. If necessary, swab out conduits
prior to installing the conductors.

• Install drain fittings at the lowest point in the conduit run; install seals at the point of

entry to the gas chromatograph (GC) to prevent vapor passage and accumulation of
moisture.

• Use liquid-tight conduit fittings for conduits exposed to moisture.

When a conduit is installed in hazardous areas, follow these general precautions for
conduit installation:

• All conduit runs must have a fitting, which contains explosion-proof sealing (potting)

located within 3 in (76 mm) from the conduit entrance to the explosion-proof housing.
The seal should have a minimum IP rating of IP54 or equivalent NEMA®/Type rating on
the conduit sealing devices.

• The conduit installation must be vapor tight, with threaded hub fittings, sealed conduit

joints and gaskets on covers, or other approved vapor-tight conduit fittings.

WARNING

Failure to observe precautionary signs may result in serious injury or death to personnel.

Observe all precautionary signs posted on the certified explosion-proof equipment.
Consult your company's polices and procedures and other applicable documents to
determine wiring and installation practices that are appropriate for hazardous areas.

3.2.4 Sample system requirements

Line length If possible, avoid long sample lines. In long flow sample lines, velocity

can be increased by decreasing downstream pressure and using
bypass flow via a fast loop.

NOTICE

Stream switching requires a sample pressure of 20 psig (1.38 barg).

Sample line tubing material • Use sulfur-inert tubing for H2S streams; for all other applications,

use stainless steel tubing.

• Ensure tubing is clean and free of grease.

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Dryers and filters Use small sizes to minimize time lag and prevent back diffusion.

• Install a minimum of one filter to remove solid particles. Most

applications require fine-element filters upstream of the gas
chromatograph (GC). The GC includes a 2-micron filter.

• Use ceramic or porous metallic type filters. Do not use cork or felt

filters.

NOTICE

Install the probe/regulator first, immediately followed by the
coalescing filter and then the membrane filter.

Pressure regulators and
flow controllers

Pipe threads and dressings Use PTFE tape. Do not use pipe thread compounds or pipe dope.

Valving • Install a block valve downstream of sample takeoff point for

Related information

Carrier gas installation and maintenance

• Use stainless steel wetted materials.

• Parts should be rated for sample pressure and temperature.

maintenance and shutdown.

• The block valve should be a needle valve or cock valve type, of

proper material and packing, and rated for process line pressure.

3.3 Installing the analyzer

WARNING

EXPLOSION HAZARD

Failure to de-energize the analyzer may cause an explosion and severely injure personnel.

Do not open the enclosure unless the area is known to be non-hazardous or unless all
devices within the enclosure have been de-energized.

Do not restore power after opening the enclosure until it has been purged for 60
minutes at a pressure of 0.3 in. w.c.

3.3.1 Connect power to the gas chromatograph (GC)

WARNING

ELECTRIC SHOCK

Failure to observe all safety precautions could result in serious injury or death.

Do not connect AC power leads without first ensuring that the AC power source is
switched off.

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Figure 3-1: Circuit Breaker

A. Electronics enclosure

B. Circuit breaker

Procedure

1. Locate the three leads for connecting power to the GC.
The leads are colored as follows:

GC power wiring

Hot Black

Neutral White

Ground Green

Color

2. Connect the leads to the AC power source (i.e., with circuit breaker and power
disconnect switch).

Make power line splices and conduit seals that comply with applicable electrical
code and hazardous area wiring requirements.

WARNING

ELECTRIC SHOCK

Failure to properly connect the GC unit may result in serious personal injury.

Do not apply power to the GC until all power, interconnection, and external signal
connections have been verified and proper grounds have been made.

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3. If necessary, connect the analyzer's chassis ground to an external copper ground
rod (at remote locations).

4. Close the electronics enclosure door and apply power to the GC.

3.3.2 Connect gas lines

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Procedure

1. Remove the plug from the 1/16-in sample vent tubing marked SV1 that is located
on the flow panel assembly.

Figure 3-2: Sample vent and measure vent lines

A. Sample and gas line vents

• If desired, connect the sample vent lines to an external, ambient pressure vent. If

the vent line is terminated in an area exposed to wind, protect the exposed vent
with a metal shield.

• Use ¼-in or ⅜-in tubing for vent lines longer than 10 ft (3.05 m).

NOTICE

Do not discard the vent line plugs. They are useful when leak-checking the gas
chromatograph (GC) and its sample or gas line connections.

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At this stage in the installation, the measure vent (MV) lines (labeled on the side of
the GC) should remain plugged until the GC has been checked for leaks. For regular
operation, however, the MV lines must be unplugged.

2. Connect the carrier gas to the GC.
The carrier gas inlet is labeled Carrier In and is a ¼-in T-fitting.

WARNING

EXPLOSION HAZARD

Failure to follow this warning may result in injury or death to personnel.

Do not turn on sample gas until you have completely checked the carrier lines for
leaks.

• Use stainless steel tubing to convey carrier gas.

• Use a dual-stage regulator with high-side capacity of 3,000 psig (206.84 barg)

and low-side capacity of 150 psig (10.34 barg).

• Carrier gas is fed from two bottles for carrier gas plumbing.

3. Connect calibration standard gas to the GC.

When installing the calibration standard gas line, ensure that the correct tubing
connection is made.

• Use ⅛-in stainless steel tubing to connect calibration standard gas unless the

application requires treated tubing.

• Use a dual-stage regulator with low-side capacity of up to 30 psig (2.07 barg).

4. Connect sample gas stream(s) to the GC.

• Use ⅛-in stainless steel tubing, as appropriate, to connect sample gas.

• Unless stated otherwise in the product documentation, ensure that the pressure

of the calibration and sample line is regulated at 15 psig (1.03 barg) to 20 psig
(1.38 barg).

Postrequisites

After all lines have been installed, proceed with leak-checking the carrier and sample lines.

Related information

Carrier gas installation and maintenance

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3.3.3 Flame photometric detector (FPD) gas connections

CAUTION

If you use 316 or other stainless steel tubing instead of sulfur-inert tubing, the sulfur
components will adhere to the internal surface of the tubing and will continue to do so
until the entire internal surface is coated. This results in lower than expected levels of
sulfur components reaching the detector for measurement.

Use sulfur-inert tubing for all calibration gas and process gas connections going to and
from the FPD. All internal process pipework, columns, etc. are sulfur-inert tubing by
design.

3.3.4 Maximum effective distance by communication protocol type

Table 3-1 lists the maximum distance at which the indicated protocol can transmit data

without losing effectiveness. If you need longer runs, use a repeater or other type of
extender to maintain the protocol's efficiency.

Table 3-1: Maximum distance for each communication protocol

Communication protocol Maximum distance

RS-232 50 ft (15 m)

RS-422/RS-485 4,000 ft (1,219 m)

Ethernet (CAT5) 300 ft (91 m)

3.3.5 RS-485 serial port terminating resistors

To ensure correct communication with all hosts, place a 120-ohm terminating resistor
across the gas chromatograph (GC) serial port terminals on the RS-485 link. On a
multi-dropped link, install the terminating resistor on the last controller link only.

3.3.6

Configuring communications

The Rosemount 1500XA has four serial communications ports: Port 0, Port 1, Port 2, and
Port 3 (which is a dedicated personal computer [PC] to gas chromatograph [PC] port). The
mode for each of the first three ports can be set to RS-232, RS-422, or RS-485. These port
configurations are normally specified by the customer at the time of order and then set at
the factory, but they can be changed at any time with Rosemount MON2020.

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Figure 3-3: RS-232, RS-485 and RS-422 Port Configurations

Install optional RS-232 serial ports

You can install an optional RS-232 board in one or both of the expansion in/out (I/O) slots
provided on the gas chromatograph's (GC's) card cage in the electronics enclosure.

You can use this extra port for Modbus® ASCII/RTU communications or to connect directly
to a computer installed with Rosemount MON2020.

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Figure 3-4: RS-232 connections

Terminal Label Definition

1 RX Receive

2 TX Transmit

3 RTS Request to send

4 DTR Data termininal ready

5 GND Ground

Procedure

1. Start Rosemount MON2020 and connect to the GC.

2. Select Tools → I/O Cards.

3. Identify the appropriate card slot under the Label column and then select
Communications module - RS232 from the appropriate Card Type drop-down list.

4. Click OK.

5. Turn off the GC.

6. Install the RS-232 board into the appropriate I/O card slot in the GC’s card cage.

7. Close and secure the electronics enclosure door.

8. Apply power to start the GC.

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Install an optional RS-485/RS-422 serial port card

You can install an optional RS-485 board in one or both of the expansion in/out (I/O) slots
provided with the gas chromatograph's (GC's) card cage in the electronics enclosure. You
can configure this card to RS-422 (four wire) or RS-485 (two wire) mode.

RS-485 mode is the default setting. See Emerson.com/ROC800-Series.

Procedure

1. Start Rosemount MON2020 and connect to the GC.

2. Go to Tools → I/O Cards.
The I/O Cards window displays.

3. Identify the appropriate card slot under the Label column and then select
Communications module - RS422/485 from the appropriate Card Type drop-down
list.

Figure 3-5: Rosemount MON2020 I/O Cards window

4. Click OK.

5. Turn off the GC.

6. Install the RS-485/RS-422 serial port card into the appropriate expansion slot in the
GC’s card cage.

7. Close the electronics enclosure door and start the GC.

Related information

Configuring the optional RS-485 serial port to function as an RS-422 serial port

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Configuring the optional RS-485 serial port to function as an RS-422 serial port

See Figure 3-6 and Table 3-2 for the correct jumper settings to configure the optional
RS-485 serial port to function as an RS-422 serial port:

Figure 3-6: RS-485/RS-422 jumper settings on serial board

A. J3 (RS-485 two wire) (RS-422 four wire)

B. J4 (Termination OUT, IN)
C. J5 (RS-485 two wire) (RS-422 four wire)
D. J6 (Termination OUT, IN)

Table 3-2: Configuring the serial connections for RS-485/RS-422 serial
communications

Jumpers RS-485 (half duplex/2-wire) RS-422 (full duplex/4-wire)

J3 Half Full

J5 Half Full

Termination IN Termination OUT

J4 In Out

J6 In Out

TB1 wire terminals RS485 (half duplex/2-wire) RS422 (full duplex/4-wire)

A RxTx+ Rx+

B RxTx- Rx-

Y Normally closed Tx+

Z Normally closed Tx-

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3.3.7 Connect directly to a personal computer (PC) using the gas chromatograph's (GC’s) Ethernet1 port

The GC’s DHCP server feature and its Ethernet1 port on the backplane at J22 allows you to
connect directly to the GC. This is a useful feature for GCs that are not connected to a local
area network; all that is needed is a PC, typically a notebook computer, and a CAT5
Ethernet cable.

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Note

The PC must have an Ethernet network interface card (NIC) that supports the automatic
medium-dependent interface crossover (Auto-MDIX) technology and either an Ethernet
cable of at least CAT5 or an Ethernet Crossover Cable of at least CAT5.

Note

The backplane has two switches located at SW1. The first switch is used for starting the
DHCP server. The second switch is reserved for future use.

Note

The GC can be connected (or remain connected) to the local network on Ethernet2 (TB11)
on the backplane while the DHCP feature on Ethernet1 is being used.

The backplane has two Ethernet ports:

Table 3-3: Ethernet connections on the backplane

Name Location Connector type

ETHERNET1 J22 RJ45 (DHCP-enabled)

ETHERNET2 TB11 4-wire terminal block

Figure 3-7: Ethernet ports on the backplane

A. Ethernet1 (RJ45) port

B. Ethernet2 (four-wire) port

Procedure

1. Plug one end of the Ethernet cable into the PC’s Ethernet port and the other end
into the GC’s RJ45 socket on J22 on the backplane.

2. Locate switch at SW1 directly between Ethernet1 and Ethernet2 ports on the back
plane. Place SW1 in the On position.

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Figure 3-8: SW1 switch on the backplane

A. Backplane SW1

Note

The GC can be connected (or remain connected) to the local network on Ethernet2
(TB11) on the backplane while the DHCP feature on Ethernet1 is being used.

This starts the GC’s DHCP server feature. The server typically takes approximately
20 seconds to initialize and start up.

3. Wait for 20 seconds and then do the following to ensure that the server has
provided an Internet protocol (IP) address to the PC:

a) From the PC, go to Start → Control Panel → Network Connections.

The Network Connections window lists all dial-up and local area network
(LAN)/high-speed Internet connections installed on the PC.

b) In the list of LAN / high speed Internet connections, find the icon that

corresponds to the PC-to-GC connection and check the status that displays
beneath the Local Area Connection.
It should show the status as Connected. The PC is now capable of connecting
to the GC.

If the status is Disconnected, it may be that the PC is not configured to
accept IP addresses; therefore, do the following:

4. Right-click the Properties icon.
The Local Area Connection Properties window displays.

5. Scroll to the bottom of the Connection list box and select Internet Protocol (TCP/
IP).

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6. To configure the PC to accept IP addresses issued from the GC, select the Obtain an
IP address automatically and Obtain DNS server address automatically check
boxes.

7. Click OK to save the changes and to close the Internet Protocol (TCP/IP) Properties
window.

8. Click OK to close the Local Area Connection Properties window.

9. Return to the Network Connections window and confirm that the appropriate icon’s
status reads Connected.

Postrequisites

If the icon still reads Disconnected refer to Troubleshoot DHCP connectivity issues.

NOTICE

If you power cycle the GC, you will lose connectivity.

Related information

Connect directly to a personal computer (PC) using the gas chromatograph's (GC’s) wired Ethernet2 terminal

Connect to the gas chromatograph (GC) using Rosemount MON2020
Troubleshoot DHCP connectivity issues

3.3.8

3.3.9

Connect to the gas chromatograph (GC) using Rosemount MON2020

To connect to the GC using the RJ45 Ethernet1 connection:

Procedure

1. Start Rosemount MON2020.
The Connect to GC window displays.

2. Locate the default Direct-DHCP under the GC Name column.

This GC directory is created automatically when Rosemount MON2020 is installed.
You can rename the GC, but do not change the IP address that it references,

192.168.135.100.

3. Click the associated Ethernet button.
Rosemount MON2020 prompts you to enter a user name and password.

4. Enter your user name and password.

5. Rosemount MON2020 connects you to the GC.

Connect directly to a personal computer (PC) using the
gas chromatograph's (GC’s) wired Ethernet2 terminal

The Rosemount 1500XA has a wired Ethernet2 terminal at TB11 on the backplane that you
can connect to with a static Internet protocol (IP) address. All that is needed is a PC,

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typically a notebook computer, and a two-wire, twisted pair CAT5 Ethernet cable with one
of its plugs removed to expose the wires.

Figure 3-9: Crimped CAT5 cable

NOTICE

The GC can be connected (or remain connected) to the local network on Ethernet2 (TB11)
on the backplane while the DHCP feature is being used.

Figure 3-10: Wired Ethernet2 terminal block on the backplane

A. TB11 four wire Ethernet2 connector

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Procedure

1. Use the following schematics as a guide to wiring the GC via its four-wire connector
at TB11.

Figure 3-11 shows the traditional wiring scheme. Figure 3-12 shows how to wire a

CAT5 cable without the RJ45 plug.

Figure 3-11: Field wiring to TB11

Figure 3-12: CAT5 wiring to TB11

2. Once you have wired the cable to the Ethernet terminal, plug the other end into a
PC or a wall jack.

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Related information

Assign a static Internet protocol (IP) address to the gas chromatograph (GC)

3.3.10 Connect directly to a personal computer (PC) using the gas chromatograph's (GC's) serial port

The GC’s serial port at J23 on the back plane allows a PC with the same type of port to
connect directly to the GC. This is a useful feature for a GC that is located in an area
without Internet access; all that is needed is a PC running Microsoft® Windows™ and a
straight-through serial cable.

Figure 3-13: J23 Serial Port on the Back Plane

A. Back plane RS-232 serial port

To set up the PC for the direct connection:

Procedure

1. Install the communications cable between two computers:
a) Navigate to Start → Control Panel and select the Phones and Modem

Options icon.
The Phones and Modem Options dialog displays.

b) Select the Modem tab and click Add….

The Add Hardware Wizard displays.

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c) Select the Don’t detect my modem; I will select it from a list check box and

then click Next.

d) Click Have Disk.

The Install from Disk dialog appears.

e) Click Browse.

The Browse dialog displays.

f) Navigate to the Rosemount MON2020 install directory (typically C:\Program

Files (x86)\Emerson Process Management\MON2020) and select Daniel Direct
Connection.inf.

g) Click Open.

You will be returned to the Install from Disk dialog.

h) Click OK.

You will be returned to the Add Hardware Wizard.

i) Click Next.

j) Select an available serial port and click Next.

The Hardware Installation dialog displays.

k) Click Continue Anyway.

After the driver is installed, you will be returned to the Add Hardware Wizard.

l) Click Finish.

You will be returned to the Phones and Modems dialog. The Daniel Direct
Connect modem should be listed in the Modem column.

2. Start Rosemount MON2020 and create a GC connection for the Daniel Direct

Connection modem:

a) Go to File → GC Directory.

The GC Directory window displays.

b) Go to File → Add.

The software adds a New GC row to the bottom of the table.

c) Select the New GC text and type a new name for the GC connection.

d) Select the new GC’s Direct check box.

e) Click the Direct button located at the bottom of the GC Directory window.

The Direct Connection Properties window displays.

f) Go to Port → Communications cable between two computers (COM n).

Note

The letter n stands for the COM port number.

g) Go to Baud Rate → 57600.

h) Click OK to save the settings.

You will be returned to the GC Directory window.

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i) Click OK to save the new GC connection and to close the GC Directory

window.

3. Connect one end of the direct connect cable to the GC’s serial port at J23 on the

back plane.

4. Connect the other end of the direct connect cable to the PC’s corresponding serial

port.

5. Go to Chromatograph → Connect....

The Connect to GC window displays.

6. Click Direct to connect to the GC using the serial cable connection.

3.3.11 Assign a static Internet protocol (IP) address to the gas chromatograph (GC)

Procedure

1. Start Rosemount MON2020 and log in to the GC using a direct Ethernet connection.

2. Go to Application → Ethernet ports....

The Ethernet Ports window displays.

3. Depending upon the Ethernet port to which you want to assign a static IP address,
do the following:

a) The Ethernet port at TB11: Enter the appropriate values in the Ethernet2 IP

Address, the Ethernet 2 Subnet, and the Default Gateway fields.

b) The RJ45 Ethernet port at J22: Enter the appropriate values in the Ethernet1

IP Address, the Ethernet1 Subnet, and the Default Gateway fields.

Note

See your information technology (IT) staff to obtain IP, subnet, and gateway
addresses.

Important

To configure a Ethernet IP address using the local operator interface (LOI),
refer to Figure C-47.

4. Click OK.

5. Log off the GC.

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6. Access the backplane, which is located in the GC’s upper enclosure.

Figure 3-14: Port locations on the backplane

A. J22 Ethernet 1
B. Switch SW1
C. TB11 Ethernet2

7. If you are setting up a static IP address for the Ethernet1 port at J22, and you also
intend to connect to your company’s local area network, do the following:

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a) Locate the switch, at SW1 on the backplane.

SW1 is located between the Ethernet port at J22 and TB11, four wire
connector.

Figure 3-15: SW1 on the backplane

A. Switch SW1 on the backplane

b) Use a Phoenix screwdriver and move the dip switch to the OFF position.

This disables the DHCP server.

8. To connect to the GC:

a) Start Rosemount MON2020 and select File → GC Directory....

The GC Directory window displays.

b) Select Add.

Rosemount MON2020 adds a new GC profile to the end of the table.

Note

You can name the GC’s profile as well as add a short description.

c) Select the new profile and click Ethernet... Enter the GC’s static IP address in

the IP address field.

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d) Click OK.

The Ethernet Connection Properties for New GC window closes.

9. Click Save to save the new profile.

10. Click OK to close the GC Directory window.

3.3.12

11. Select Chromatograph → Connect... to connect to the GC or click
The Connect to GC window displays. The newly created GC profile should be listed in
the table.

12. Locate the new GC profile and click the Ethernet button that is associated with it.
The Login window displays.

13. Enter a User Name and User Pin and click OK.

Related information

Connect directly to a personal computer (PC) using the gas chromatograph's (GC’s)
Ethernet1 port

.

Wiring the discrete digital inputs and outputs

Wire the discrete digital inputs

WARNING

Electric shock

Failure to observe this precaution may cause serious personal injury or death.

The equipment operates using mains voltage that is dangerous to life. Make sure that the
circuit breakers are set to OFF and tagged off before opening the electronics enclosure.

To connect digital signal input lines to the gas chromatograph (GC):

Procedure

1. Disconnect power to the analyzer and allow the components to cool for at least five
minutes.

2. Open the electronics enclosure door and access the back plane.

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3. Make the digital input wiring connections on the back plane at TB7.

Figure 3-16: Digital Inputs: TB7 on the back plane

A. TB7 connector

Note

The discrete digital input terminals on the back plane are self-powered. Devices
connected to the digital input will be powered by the GC's dedicated isolated 24 V
power supply.

Note

The discrete digital input terminals are optically isolated from the GC's other
circuitry.

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4. Route digital in/out (I/O) lines away from the sensitive detector lines (on the left
side of the back plane) and away from the analog inputs and outputs.

There are connections for five digital inputs on the back plane at TB7, as indicated in

Table 3-4.

Table 3-4: Discrete digital inputs at TB7

TB7 Function

Pin 1 Digital input 1

Pin 2 Digital input return

Pin 3 Digital input 2

Pin 4 Digital input return

Pin 5 Digital input 3

Pin 6 Digital input return

Pin 7 Digital input 4

Pin 8 Digital input return

Pin 9 Digital input 5

Pin 10 Digital input return

Related information

Engineering drawings

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Wiring the discrete digital outputs

The discrete outputs are located on TB3, which is a 15-pin connector, and have five Form­C relays on the backplane. All contact outputs have a rating of 1A at 30 Vdc.

Figure 3-17: Digital outputs: TB3 on the back plane

A. TB3 Discrete digital output termination block

Table 3-5 lists the discrete digital output function for each pin on the TB3 connector.

Table 3-5: Discrete digital outputs on TB3

TB3 Function

Pin 1 Normally closed (NC1)

DIG_OUT NC1

Pin 2 ARM1

DIG_OUT ARM1

Pin 3 Normally open (NO1)

DIG_OUT NO1

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Table 3-5: Discrete digital outputs on TB3 (continued)

TB3 Function

Pin 4 NC2

DIG_OUT NC2

Pin 5 ARM 2

DIG_OUT ARM2

Pin 6 NO2

DIG_OUT NO2

Pin 7 NC3

DIG_OUT NC3

Pin 8 ARM3

DIG_OUT ARM3

Pin 9 NO3

DIG_OUT NO3

Pin 10 NC4

DIG_OUT NC4

3.3.13

Pin 11 ARM4

DIG_OUT ARM4

Pin 12 NO4

DIG_OUT NO4

Pin 13 NC5

DIG_OUT NC5

Pin 14 ARM5

DIG_OUT ARM5

Pin 15 NO5

DIG_OUT NO5

Note

Form-C relays are single-pole double-throw (SPDT) relays that have three positions:
normally closed (NC); an intermediate position, also called the make-before-break
position (ARM); and normally open (NO).

Wiring the analog inputs

All Rosemount 1500XA gas chromatographs (GCs) have at least two analog inputs. An
additional four analog inputs are available with a ROC800 AI-16 card that can be installed
into one of the optional slots in the card cage.

Related information

Wire a ROC800 digital output (DO) module

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Analog inputs on the backplane

There are two analog input connections on the backplane at terminal block 10 (TB10).

Figure 3-18: Analog inputs: TB10 on the back plane

A. TB10

Table 3-6: Analog inputs TB10

TB10 Function

Pin 1 +AI_1

Pin 2 -AI_1

Pin 3 +AI_2

Pin 4 -AI_2

Analog inputs settings

Figure 3-19 shows how to wire two analog inputs (TB10).

These analog inputs are set to accept a current (4-20 mA) source.

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Figure 3-19: Customer wiring for analog inputs

A. Back plane

B. Analog inputs
C. Analog input 1
D. Analog input ground

E. Analog input 2

F. Cable
G. Customer devices
H. Customer 4-20 mA outputs

Select the input type for an analog input

You can set an analog input to either voltage (0-10 V) or current (4-20 mA) accessed from
the Rosemount MON2020 Hardware → Analog Inputs menu.

Procedure

1. Start Rosemount MON2020 and connect to the GC.

2. Select Hardware → Analog Inputs....

The Analog Inputs window displays.

3. To set the analog input to current, select mA from the mA/Volts drop-down list for

the appropriate analog input; to set the analog input to voltage, select Volts from
the mA/Volts drop-down list for the appropriate analog input.

4. Click Save to save the changes and keep the window open or click OK to save the

changes and close the window.

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Typical wiring for line-powered transmitters

Figure 3-20 shows the most common wiring plan for supplying power to two 4-20 mA

transmitters, such as pressure sensor transmitters.

Figure 3-20: Typical wiring for line-powered transmitters

3.3.14

A. Back plane

B. Customer transmitter
C. Analog inputs
D. Transmitter 4-20 mA output

Analog output wiring

The Rosemount 1500XA has at least six analog outputs. An additional four analog inputs
are available with an ROC800 AO card that can be installed into one of the optional slots in
the card cage.

Analog outputs on the back plane

There are six analog output connections on the back plane at TB4 and TB30.

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Figure 3-21: Analog Outputs TB4 and TB30

A. TB4

B. TB30

Table 3-7: Analog Outputs: Back Plane TB4 24 V External Power

TB4 Function

Pin 1 Extra power 1

Pin 2 4-20mA_1+

Pin 3 Ground

Pin 4 Extra power 2

Pin 5 4-20mA_2+

Pin 6 Ground

Pin 7 Extra power 3

Pin 8 4-20mA_3+

Pin 9 Ground

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Table 3-8: Analog Outputs: Back Plane TB30 24 V External Power

TB30 Function

Pin 1 Extra power 4

Pin 2 4-20mA_4+

Pin 3 Ground

Pin 4 Extra power 5

Pin 5 4-20mA_5+

Pin 6 Ground

Pin 7 Extra power 6

Pin 8 4-20mA_6+

Pin 9 Ground

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Factory settings for analog outputs

Figure 3-22 shows how to wire up to six devices to the analog outputs that are located on

the back plane.

Figure 3-22: Wiring for six analog outputs

A. Back plane

B. Customer devices
C. 4-20 mA inputs
D. Ground

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Wire customer externally-powered analog outputs

It is possible to furnish power to each analog output while maintaining isolation between
channels.

Consult Figure 3-23 before wiring a customer-powered device:

Procedure

Use Figure 3-23 to provide power wiring to each analog output while maintaining isolation
between channels.

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Figure 3-23: Wiring for customer-powered analog outputs

A. Back plane
B. Customer devices
C. Extra power

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shows the settings for the analog outputs switches, located on the base in/out (I/O) board,
that are necessary to provide power to each analog output while maintaining isolation
between channels.

The settings for the analog outputs connections, located on the back plane are necessary
to provide power to each analog output while maintaining isolation between channels.

Refer to Table 3-9 and Table 3-10 for External 24 V loop power.

Table 3-9: Analog Outputs: Back Plane TB4 24 V External Power

TB4 Function

Pin 1 Extra power 1

Pin 2 4-20mA_1+

Pin 3 Ground

Pin 4 Extra power 2

Pin 5 4-20mA_2+

Pin 6 Ground

Pin 7 Extra power 3

Pin 8 4-20mA_3+

Pin 9 Ground

Table 3-10: Analog Outputs: Back Plane TB30 24 V External Power

TB30 Function

Pin 1 Extra power 4

Pin 2 4-20mA_4+

Pin 3 Ground

Pin 4 Extra power 5

Pin 5 4-20mA_5+

Pin 6 Ground

Pin 7 Extra power 6

Pin 8 4-20mA_6+

Pin 9 Ground

3.3.15 Optional digital and analog inputs and outputs

Optional discrete digital inputs (DI)

When plugged into one of the optional card slots in the card cage, the Emerson ROC800
DI card provides eight additional discrete digital inputs. The discrete digital inputs can

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monitor the status of relays, open-collector or open-drain type solid-state switches, and
other two-state devices.

For more information, see ROC800-Series Discrete Input Module at Emerson’s ROC 800-

Series website.

Figure 3-24: Optional digital in/out (I/O) modules

Wire a ROC800 digital input (DI) module

To connect the ROC800 DI module to a field device:

Procedure

1. Expose the end of the wire to a maximum length of 0.25 in (6.4 mm).

2. Insert the exposed end into the clamp beneath the termination screw.

3. Tighten the screw.

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Figure 3-25: Typical wiring

A. Control

B. Discrete device (externally powered)

Table 3-11: ROC800 discrete digital wiring

Terminal Label Definition

1 1 Channel 1 Positive

2 2 Channel 2 Positive

3 3 Channel 3 Positive

4 4 Channel 4 Positive

5 5 Channel 5 Positive

6 6 Channel 6 Positive

7 7 Channel 7 Positive

8 8 Channel 8 Positive

9 COM Common

10 COM Common

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Wire a ROC800 digital output (DO) module

Figure 3-26: Discrete discrete output wiring

A. Control

B. Discrete device (externally powered)

Terminal

1 1+ Positive discrete output

2 COM Discrete output return

3 2+ Positive discrete output

4 COM Discrete output return

5 3+ Positive discrete output

6 COM Discrete output return

7 4+ Positive discrete output

8 COM Discrete output return

9 5+ Positive discrete output

10 COM Discrete output return

Label Definition

To connect the ROC800 DO module to a field device:

Procedure

1. Expose the end of the wire to a maximum length of 0.25 in (6.4 mm).

2. Insert the exposed end into the clamp beneath the termination screw.

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3. Tighten the screw.

Optional analog inputs (AI)

When plugged into one of the optional card slots on the card cage, the ROC800 AI-16 card
provides four additional analog inputs.

The AI channels are scalable, but are typically used to measure either a 4-20 mA analog
signal or a 1-5 Vdc signal. If required, the low end of the AI module’s analog signal can be
calibrated to zero. For more information, see Analog Input Modules (ROC800 Series).

Figure 3-27: Optional analog expansion card slots

A. Optional I/O expansion card slots

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Wire a ROC800 AI-16 module

Figure 3-28: Typical ROC800 wiring

A. 1-5 volt device, externally powered

B. 1-5 volt device, ROC800 powered
C. Current loop device 4-20 mA, ROC800 powered

To connect the ROC800 AI-16 module to a device:

Procedure

1. Expose the end of the wire to a maximum length of 0.25 in (6.4 mm).

Note

We recommend twisted-pair cables for in/out (I/O) signal wiring. The module’s
terminal blocks accept wire sizes between 12 and 22 American wire gauge (AWG).
Allow some slack when making connections to prevent strain.

2. Insert the exposed end into the clamp beneath the termination screw.

3. Tighten the screw.

There are two dip switches on the terminal block side of the module that can be
used to set a 250 Ω resistor in or out of circuit for each analog input.

To put an analog input’s resistor in circuit, flip the appropriate dip switch to I; to put
an analog input’s resistor out of circuit, flip the appropriate dip switch to V.

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Calibrate a ROC800 AI-16 module

Prerequisites

To calibrate the ROC800 AI-16 module you must have a personal computer (PC) with the
ROCLINK™ 800 Configuration software installed and open.

See Emerson’s ROC 800-Series page for details, downloads, and manuals.

Procedure

1. Go to Configure → I/O → RTD Points → Calibration.

2. Select an analog input.

3. Click Update to request one value update from the input.

4. Click Freeze to stop the values of the input from being updated during calibration.

Note

If you are calibrating a temperature input, disconnect the RTD sensor and connect a
decade box or comparable equipment to the RTD terminals of the ROC card.

5. Click Calibrate.

6. Enter a value for Set Zero after stabilization.

7. Enter a value for Set Span after stabilization.

8. Enter values for up to three Midpoints one at a time or click Done if you are not

configuring midpoints.

9. Click OK to close the main calibration window and unfreeze the associated inputs.

Postrequisites

To calibrate the inputs for another analog input, return to Step 1.

Optional analog outputs

When plugged into one of the optional card slots on the card cage, the ROC800 AO card
provides four additional analog outputs. Each channel provides a 4 to 20 mA current signal
for controlling analog current loop devices.

For more information, see Emerson's ROC 800-Series website.

Connect ROC800 analog output (AO) module to a field device

Procedure

1. Expose the end of the wire to a maximum length of 0.25 in (6.4 mm).

Note

We recommend using twisted-pair cables for in/out (I/O) signal wiring. The
module’s terminal blocks accept wire sizes between 12 and 22 American wire
gauge (AWG). Expose minimal bare wire to prevent short circuits. Allow some slack
when making connections to prevent strain.

2. Insert the exposed end into the clamp beneath the termination screw.

3. Tighten the screw.

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4. Close the electronics enclosure door and apply power to the gas chromatograph

(GC).

5. Run Rosemount MON2020 and connect to the GC.

3.4 Leak checking and purging for first calibration

CAUTION

EQUIPMENT DAMAGE

Failure to clean and dry the tubing may compromise the integrity of the analyzer or its
warranty.

Make sure all tubing is clean and dry internally.
Prior to installation, blow the tubing free of internal moisture, dust, or other

contaminants.

Verify that all electrical connections are correct and safe and then turn the gas
chromatograph (GC) on.

3.4.1

Check the gas chromatograph (GC) for leaks

Prerequisites

Leak checking carrier and calibration gas lines requires power and a personal computer
(PC) connected to the GC.

Note

Refer to the analyzer's drawing documentation package that shipped with the GC for leak
checking and identifying vents.

Emerson tested the GC and fittings for leaks at the factory prior to shipment.

Procedure

1. Plug the measure vent (labeled MV) vent line if it is open.

Leave the SV or sample vent line open or unplugged.

2. Slowly pressurize each line in turn; then block in the line, making sure the pressure

holds.
For example, the carrier gas line should be slowly brought up to 100 psig

(6.89 barg)± two percent with the dual-stage regulator at the carrier gas cylinder,
and the actuation pressure should be 100 psig (6.89 barg) maximum.

3. After two minutes, shut the carrier gas bottle valve and observe the high side

regulator gauge on the carrier gas bottle.

a. The gauge should not bleed down more than 100 psig (6.89 barg) in ten

minutes.

b. If helium is lost at a faster rate, leaks are usually found between the carrier

gas bottle and the analyzer. Check and tighten all connections, as well as the
dual-stage regulator.

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4. When the leak check is complete, reopen the helium bottle valve. Remove the plug

from the MV line.

5. Shut the metering valve below the rotameter on the front of the flow panel.

Leave the metering valve shut for now; you will reopen it later during initial purging
and the analyzer's first calibration.

6. Repeat the procedure with sample gas and stream gas.

Note

Do not use a liquid leak detector, such as Snoop®, on the valves or components in
the oven.

Note

Refer to the Flow Configuration schematic in the documentation packet that
shipped with the GC for detailed instructions on plugging the flame ionization
detector (FID) and flame photometric detector (FPD) vents.

3.4.2

Purge carrier gas lines

Prerequisites

Purging carrier and calibration gas lines requires power and a personal computer (PC)
connected to the gas chromatograph (GC).

Procedure

1. Ensure that the vent line plugs have been removed and the vent lines are open.

2. Ensure that the carrier gas bottle valve is open.

3. Set the GC side of the carrier gas to 115 psig (7.93 barg).

4. Turn on the GC and the PC.

5. Start Rosemount MON2020 and connect to the GC.

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6. Select Hardware → Heaters....

The Heaters window displays.

Figure 3-29: Heaters window

3.4.3

7. Allow the GC system temperature to stabilize and the carrier gas lines to become

fully purged with carrier gas, which usually takes at least an hour.
The temperature values for the heaters should indicate that the GC is warming up.
The Status column displays OK.

8. Select Control → Auto Sequence....

Note

You can also perform Step 6 through Step 8 with the local operator interface (LOI).

Important

Emerson recommends a continuous operation without sample gas for a period of
four to eight hours (or overnight), during which no changes should be made to the
settings described in Step 1 through Step 7.

Purge calibration gas lines

Prerequisites

Purging calibration gas lines requires power and a personal computer (PC) connected to
the gas chromatograph (GC).

Procedure

1. Ensure that the carrier gas lines have been fully purged and that the sample vent

plugs have been removed.

2. Close the calibration gas bottle valve.

3. Fully open the block valve associated with the calibration gas feed.

Refer to the Rosemount MON2020 Software for Gas Chromatographs Reference

Manual for instructions on selecting streams.

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4. Open the calibration gas bottle valve.

5. Increase the outlet pressure to 15 psig (1.03 barg), plus or minus five percent, at the

calibration gas bottle regulator.

6. Close the calibration gas bottle valve.

7. Let both gauges on the calibration gas bottle valve bleed down to 0 psig

(0.00 barg).

8. Repeat Step 4 through Step 7 five times.

9. Open the calibration gas bottle valve.

3.5 Start up the system

Procedure

1. For system start-up, run a single-stream analysis of the calibration gas.

a) Verify the calibration stream is set to Auto.

b) Use Rosemount MON2020 to run a single stream analysis on the calibration

stream. Once proper operation of the GC is verified, halt the analysis by

selecting Control → Halt....

3.5.1

Note

Example go to MON2020 → Control → Single Stream → Calibrate menu
path and select the associated analysis stream.

Unless stated otherwise in the product documentation, ensure that the
pressure of the calibration and sample line is regulated at 10 to 30 psig (0.7
to 2.1 BarG). 15 psig (1 BarG) is recommended.

c) Validate calibration gas and retention times and run a manual calibration.

d) Go to MON2020 → Application → Component Data and select the

associated stream. Check the Component Data table for calibration gas
validation information and retention times.

e) Go to MON2020 → Control → Calibration and select the analysis stream to

run a manual calibration. Select the Purge stream for 60 seconds checkbox
and Normal calibration type radio button; then click OK.

2. Select Control → Auto Sequence... to start auto sequencing of the line gas

stream(s).

The gas chromatograph (GC) begins the auto sequence analysis.

Flame ionization detector (FID) configuration

When connected to the gas chromatograph (GC) via Rosemount MON2020, select
Hardware → Detectors to access the Detectors dialog.

Refer to the Rosemount MON2020 Software for Gas Chromatographs Reference Manual
for additional configuration details.

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Figure 3-30: Rosemount MON2020 - Detectors window

Halt the analysis: Control → Halt (F3).

Configure the following fields from the Detectors dialog:

• FID Ignition - Manual or Automatic

• Ignition Attempts

• Wait Time Bet (between) Tries

• Igniter On duration

• Flame On Sense Temp

• Flame Out Sense Temp

• Electrometer Voltage

Note

If the FID does not appear in the Detectors window your gas chromatograph (GC) may not
be fitted with an FID.

3.6 Start a 2-point calibration

The 2-point calibration process calculates an exponential power fit that the gas
chromatograph (GC) uses to accurately analyze a sample stream with a flame photometric
detector (FPD).

Prerequisites

The 2-Point calibration process requires two calibration gases that will be used to generate
the data for the exponential power fit calculation. While both calibration gases should
have the same components, one of the calibrations gases, called the low calibration gas
(LCG), should have a lower concentration of the components than the other calibration

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gas, which is called the high calibration gas (HCG). The GC can then compute the
coefficients for the 2-point (2-Pt) exponential power fit by doing a single-level calibration
on these individual LCG and HCG streams.

Procedure

1. Start Rosemount MON2020 and press F6 to open the Component Data window.

2. Change the Calib Type for the target component to 2 pt Calib.

3. For the target component, select the component data table (CDT) that is associated

with the LCG from the 2 Pt Calib High CDT drop-down list.

4. For the target component, select the CDT that is associated with the HCG from the

2 Pt Calib High CDT drop-down list.

5. Run a single stream analysis on the stream associated with the LCG until the

readings stabilize.

6. Run a forced calibration on the stream associated with the LCG.

7. Run a normal calibration on the stream associated with the LCG.

8. Run a single stream analysis on the stream associated with the HCG until the

readings stabilize.

9. Run a forced calibration on the stream associated with the HCG.

10. Run a normal calibration on the stream associated with the HCG.
The GC is ready to analyze the sample or validation stream using the 2 Pt Exp with
the response factor that was calculated during the LCG and HCG runs.

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4 Maintaining and troubleshooting the

gas chromatograph

4.1 Maintenance and repairs in hazardous environments

DANGER

Failure to observe all precautionary signs posted on the Rosemount 1500XA can result in
injury or death to personnel.

Observe all precautionary signs posted on the gas chromatograph (GC).

Observe and follow all safety precautions and warnings before performing maintenance or
equipment repairs.

The Rosemount 1500XA enclosure is rated for a general purpose area and is certified by
CSA for Class I Division 2 Groups B, C, and D locations with a Type Z purge controller.

WARNING

EXPLOSION HAZARD

Failure to de-energize the analyzer may cause an explosion and severely injure personnel.

Do not open the enclosure unless the area is known to be non-hazardous or unless all
devices within the enclosure have been de-energized.

Do not restore power after opening the enclosure until it has been purged for 60
minutes at a pressure of 0.3 in. w.c.

Before opening the GC, reduce the risk of igniting hazardous atmospheres by
disconnecting the equipment from all power sources. Keep the assembly closed tightly
when in operation to reduce the risk of igniting hazardous atmospheres.

Incoming inlet wiring must meet local standards (such as in conduit with seal fitting within
18 in. or through cable glands). Seal all unused entries with blanks.

Please direct all health, safety, and certification related questions to your Emerson
Customer Care representative.

4.2 Troubleshooting and repair

The most efficient method for maintaining and repairing the Rosemount 1500XA is a
component-replacement concept that allows you to return the system to operation as
quickly as possible.

Use troubleshooting test procedures to identify sources of trouble, such as printed-circuit
assemblies, valves, etc., and replace them with parts in known good working order.

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4.3 Routine maintenance

The Rosemount 1500XA will perform accurately for long periods with very little attention
(except for maintaining the carrier gas cylinders).

It helps to keep a bi-monthly record of certain parameters to assure that the gas
chromatograph (GC) is operating to specifications. Fill out the maintenance checklist bi­monthly, date it, and keep it on file for access by maintenance technicians as necessary.
This gives a historical record of the operation of the Rosemount 1500XA, enables a
maintenance technician to schedule replacement of gas cylinders at a convenient time,
and allows quick troubleshooting and repair when necessary.

Also, create a diagnostic file, which contains calibration and analysis chromatograms,
alarm and event logs, analysis reports, and the complete configuration file, and file it with
the checklist, furnishing a positive dated record of the Rosemount 1500XA. You can
compare these chromatograms and reports to the chromatograms and reports run during
the troubleshooting process.

Before contacting Customer Care, connect to your GC and save the diagnostics data file.
From Rosemount MON2020, go to Tools → Save Diagnostic Data to save the diagnostic
data file.

4.3.1

Rosemount MON2020 prompts you to send an email to Customer Care (at

[e-mail]) with the diagnostic data file.

Maintenance checklist

Print the sample maintenance checklist in Figure 4-1 for your records.

If you have a problem, please complete the checklist first and have the results available, as
well as the sales order number, when calling your Emerson Customer Care representative
for technical assistance. The sales order number is on the nameplate located on the front
of the Rosemount 1500XA. Emerson files the chromatograms and reports archived when
your gas chromatograph (GC) left the factory by this number.

Note

To find the default measurements for the parameters on the checklist, use Rosemount
MON2020 to view the GC’s parameter list.

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Figure 4-1: Sample Maintenance Checklist

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4.3.2 Save diagnostic data

At least bi-monthly, create and save a diagnostic data file and check carrier and calibration
gas supplies. Fill out the checklist in Maintenance checklist (see Section 4.3.1 of

Rosemount™ 1500XA Gas Chromatograph).

4.3.3 Service programs

Rosemount Lifecycle Services offers maintenance service programs that are tailored to fit
specific requirements.

Contracts for service and repair can be arranged by contacting Lifecycle Services at the
address or telephone number on the back of this manual or visiting the website at:

Lifecycle Services.

4.4 Access to gas chromatograph (GC) components

Review Equipment description to familiarize yourself with the locations and placement of
the GC’s core components.

4.5 Precautions for handling printed circuit (PC) assemblies

Printed circuit assemblies contain complementary metal-oxide-semiconductor (CMOS)
integrated circuits, which can be damaged if the assemblies are not properly handled.

Figure 4-2: SW7 switch on the central processing unit (CPU) board

A. SW7 switch (ON is towards the dot.)

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4.6 Troubleshooting

The information is arranged either by major subsystems or by major functions of the gas
chromatograph (GC).

Note

Correct all alarms before recalibrating.

4.6.1 Hardware alarms

Use LTLOI Failure through Flame Photometric Detector Board 1 Comm Failure to identify
the alarm, potential cause, and solution for the problem.

LTLOI Failure

Recommended actions

1. Power the gas chromatograph (GC) down completely.

2. Check that the local operator interface (LOI) is connected to the backplane
board at one end and the LOI board at the other end.

3. Power up the GC.

4. If the message appears again, replace the LOI board.

Maintenance Mode

A technician has put the gas chromatograph (GC) into Maintenance mode for servicing.

Recommended action

To disable Maintenance mode, deselect the Maintenance Mode check box in the
System dialog.

Power Failure

Potential cause

The gas chromatograph (GC) has experienced a restart, caused by a power failure, since
alarms were last cleared.

Recommended action

Allow the GC to automatically restart in Warm Start mode.
During Warm Start mode, the GC does the following:

a. Waits for the heaters to stabilize.

b. Purges the sample loop.

c. Actuates the valves for two cycles.

After completing these actions, the GC switches to auto-sequence mode.

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User Calculation Failure

The gas chromatograph (GC) has detected one or more errors while parsing a user-defined
calculation.

Potential cause

This usually happens when a user-defined calculation attempts to use a system variable
that does not exist.

Recommended action

Fix the calculation that is referring to the undefined system variable.

Low Battery Voltage

The gas chromatograph (GC) has detected a low battery voltage on the central processing
unit (CPU) board.

Recommended actions

Replace the CPU board immediately to avoid losing GC configuration data.

a) Save the diagnostic data file. In Rosemount MON2020, go to Tools → Save

Diagnostic Data....

b) Power down the GC.

c) Ensure that SW7 on the CPU board is in the On position.

d) Replace the CPU board.

e) Restore configuration back to the GC. In Rosemount MON2020, go to File →

Restore Configuration to GC....

Preamp Board Comm Failure

The gas chromatograph (GC) cannot detect the preamp board.

Preamp boards 1-3.

Recommended actions

1. Power the GC down completely.

2. Check that the board is properly seated in the correct slot on the backplane.
In Rosemount MON2020, select Hardware → Installed Hardware for hardware

slot locations.

3. Power up the GC.

4. If the message appears again, replace the preamp board.

Heater Solenoid Board (1 or 2) Comm Failure

Heater/solenoid board not detected.

Recommended actions

1. Power the gas chromatograph (GC) down completely.

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2. Check that the board is properly seated in the correct slot (Heater Solenoid 1 or
Heater Solenoid 2) on the backplane.

3. Power up the GC.

4. If message appears again, replace the heater/solenoid board.

Base in/out (IO) Board Comm Failure

The gas chromatograph (GC) is not detecting the base IO (multifunction IO) board.

Recommended actions

1. Power the GC down completely.

2. Check that the board is properly seated in the correct slot on the backplane.

3. Power up the GC.

4. If message appears again, replace the base IO board.

Stream Skipped

The gas chromatograph (GC) cannot analyzer one or more streams in the stream
sequence, because the streams' Usage option is set to Unused.

Recommended actions

In Rosemount MON2020, do one of the following:

• Remove the unused stream(s) from the stream sequence.

• Change the Usage option of the stream(s) in the Streams dialog to something

other than Unused.

GC Idle

Potential cause

Someone has placed the gas chromatograph (GC) in Idle mode. The GC is not running an
analysis.

Warm Start Failed

The gas chromatograph (GC) failed to achieve desired operating conditions after power
up. The GC is unable to regulate heater zone temperature(s).

Recommended actions

1. Check heater settings in Rosemount MON2020 and the local operator interface
(LOI).

2. Check that the carrier gas cylinder pressure is at least 10 psig (0.7 BarG) above
the mechanical regulator set point.

3. Confirm that the carrier cylinder has flow to the GC.

4. Check for leaks in the carrier gas sample path.

5. Confirm that the resistance temperature devices (RTDs) are not open.

6. If necessary, replace RTD(s), heater(s), and/or regulator(s).

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Heater (1-8) Out of Range

The gas chromatograph (GC) has failed to regulate heater zone temperatures for the
indicated heater to within preset limits.

Recommended actions

1. Check temperatures within the GC, using Rosemount MON2020 or the local
operator interface (LOI).

Be aware that the GC may generate this alarm following start-up or if the set
point has been changed.

2. Check wiring, looking for splits or loose connections at the termination board
(for both the heaters and the RTDs.

3. If necessary, replace the defective heater and/or RTD.

Flame Out

Detector 1 Flame Out

The flame ionization detector (FID) or flame photometric detector (FPD) will not light or
has extinguished.

Potential cause

The FID is out.

Recommended actions

1. Use the local operator interface (LOI) or Rosemount MON2020 to ignite the
flame.

2. If unable to sustain the flame, confirm that both fuel and air cylinders are
connected and contain sufficient pressure.

3. Confirm that the fuel and set points are set to achieve the factory-desired
mixture.

4. Confirm that there is no blockage at the FID exhaust outlet, such as a cap or ice.

5. Check that the wiring connections are secure for the FID, both on the FID cap
and at the termination board.

6. If necessary, replace the FID module.

To ignite the flame manually:

1. Connect the air to the inlet and slowly bring the pressure to 60 psig (4.1 barg).

2. Connect hydrogen to the inlet and slowly bring the inlet pressure to 60 psig
(4.1 barg).

3. Remove tubing from the flame cell exhaust and use a digital flow meter to
adjust the air control valve until you obtain a reading of 160 cc/min.

4. Turn off the air supply.

5. Set the auto relight switch (S1) on the electrometer printed circuit board (PCB)
to the OVERRIDE position.

6. Use the digital flow meter to adjust the hydrogen control valve until you obtain
a reading of 100 cc/min.

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7. Turn on the air supply.

8. Set the auto relight switch (S1) on the electrometer PCB to the RUN position.
The auto relight sequence begins as follows:

a. The LED on the electrometer comes on after 10 seconds, and the glow

plug fitted to the side of the flame cell is supplied a voltage.

b. After another five seconds, the hydrogen shut-off valve operates.

c. The gas mixture ignites.

d. If the flame does not light in five seconds, the electrometer de-energizes

the hydrogen shut-off valve to stop the flow into the flame cell.

e. The flame cell is purged with air and nitrogen carrier gas.

f. The process starts again (up to ten times) until the flame stays lit.

g. If the flame does not stay lit, the LED flashes. If the alarm output is linked

to the 2350A controller discrete input, an alarm is present on the
controller.

h. Set the auto relight switch (S1) on the electrometer PCB to the RESET

position and then back to the RUN position.

i. The relight sequence restarts.

Potential cause

The FPD is out.

Recommended actions

1. In Rosemount MON2020, click Open H2 Valve.
The H2 Valve Cur State field changes to Open.

2. Click Ignite.
The Flame Status field changes when the internal temperature exceeds the
value set in the Flame On Sense Temp field.

Note

If the Flame Ignition field is set to Auto, the GC will automatically restart the
flow if it goes out.

3. If the GC fails to light after resetting the electrometer, recheck the air and
hydrogen flow.

Flame Over Temperature

Detector 1 or 2 flame over temperature.

The flame ionization detector (FID) flame temperature is above safe limits set at the
factory. The FID flame has been extinguished, the fuel supply valve closed, and automatic
analyses halted.

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Recommended actions

1. Confirm that both fuel and air cylinders are connected and contain sufficient
pressure.

2. Confirm that fuel and air set points are set to achieve desired mixture.

3. Use the local operator interface (LOI) or Rosemount MON2020 to ignite the
FID.

Detector Scaling Factor Failure

The gas chromatograph (GC) detected an excess scaling factor deviation for the detector.

Detectors 1-6.

Recommended action

Replace the preamp board.
The preamp boards for detectors 1 and 2 are located in Preamp 1.

The preamp boards for detectors 3 and 4 are located in Preamp 2.

The preamp boards for detectors 5 and 6 are located in Preamp 3.

No sample flow (1 or 2)

This alarm applies to the optional sample flow switch. The corresponding flow switch
indicates that there is no sample flow in the gas chromatograph (GC).

Recommended actions

Check the sample gas rotameter in the sample conditioning system for flow.

• If no gas flow or no rotameter is present:

a. Confirm that there is gas flow at the sample point location.

b. Ensure that the sample valves in the sample conditioning system are open.

c. Ensure that the bypass return vent path is free of obstruction.

d. Confirm that the sample line is connected from the sample point to the GC's

sample conditioning system and is free of obstruction.

e. Close the valve at the sample tap, remove pressure from the line, and check

the filters at the probe, the sample conditioning system, or both. If they are
filled with liquids or particulates, replace the filtering elements.

• If automatic stream selection valves are present, confirm that they are operating

properly.

• If a slight sample gas flow is present at the rotameter in the sample conditioning

system, drain or replace all filters.

• If you observe flow in the rotameter, replace the sample flow switch.

Loss of Purge

There is a failure in the purge operation.

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Recommended actions

1. Check that there is inert purge gas flowing into the electronics enclosure of the
gas chromatograph (GC). If not, check that the plant instrument air is
connected or repair the source of purge gas.

2. Confirm that the door to the electronics enclosure is shut and that there is no
positive pressure (above set point) present in the enclosure. If there is no
positive pressure and purge gas is flowing into the enclosure, look for damage
to the door gasket and/or bulkheads and sealing materials. Repair as needed.

3. Look for loose or disconnected terminations on the purge controller assembly.
Note that the purge controller assembly is mounted on the exterior of the GC,
but you can access its termination from the interior of the electronics
enclosure. Repair as required.

4. Replace purge controller assembly.

Low Carrier Pressure (1-4)

Input carrier pressure for the detector is below the preset limit.

Recommended actions

1. Check that the carrier cylinder pressure is at least 10 psig (0.69 barg) above the
mechanical regulator set point.

2. If input carrier pressure is low, check the carrier cylinder pressure.

3. Replace the carrier gas cylinder if required.

Analog Input (1-10) High Signal

Measured value for the indicated analog input is greater than the customer-defined full
scale range.

Analog Input (1-10) Low Signal

Measured value for the indicated analog input is lower than the customer-defined full
scale range.

Analog Output (1-10) High Signal

Measured value for the indicated analog output is greater than the customer-defined full
scale range.

Analog Output (1-10) Low Signal

Measured value for the analog output is lower than the customer-defined zero range.

Stream (1-20) Validation Failure

The most recent validation sequence for the indicated stream failed.

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Recommended actions

1. Ensure that the validation gas cylinder isolation valves are open.

2. Ensure that the validation gas regulators are set properly.

3. If the validation gas regulator pressure is below the set point, replace the gas
bottle with a full one.

4. If the gas used for validation is the same as the gas that is used for calibration,
ensure that the cylinder gas composition value listed on the cylinder's tag or on
the certificate of analysis received from the supplier matches the value
displayed in Rosemount MON2020's Component Data table.

Stream (1-20) RF Deviation

The most recent calibration sequence failed.

Recommended actions

1. Ensure that the calibration gas cylinder isolation valves are open.

2. Ensure that the calibration gas regulators' pressures are set properly and that
the cylinder is not below the set point. If the cylinder is below the set point,
replace it with a full cylinder

3. Verify that the calibration cylinder gas composition value listed on the cylinder
tag or on the certificate of analysis received from supplier matches the
calibration cylinder gas composition value displayed in Rosemount MON2020's
Component Data table. If there is a mismatch, edit the Component Data table to
reflect the correct value. Re-run the calibration sequence.

4. If the calibration is still unsuccessful, contact your Emerson representative.

Energy Value Invalid

For each configured analysis, perform a check of the analyzed energy value of the
calibration gas against the known value as part of the warm start sequence.

The Energy Value Invalid alarm is raised to instruct the associated DCS that the analyzer has
failed and all data should be ignored until a successful calibration run has been performed
to verify the analysis of the gas chromatograph (GC).

On completing warm-up, the GC performs a single analysis of the calibration stream.
Using results of the analysis, the GC calculates the energy value and compares it against
the previously entered value stored in the tables.

If the calculated energy value is within the allowable limits set up by the operator, the
Energy Value Invalid alarm is cleared, and the GC returns to normal operation; otherwise,
the Energy Value Invalid alarm remains active.

Recommended actions

1. Ensure that correct calibration gas energy value and limits have been entered in
the Component Data Table → Edit Energy Value dialog.

2. Ensure the calibration gas bottle is open and not low or empty.

3. Check analyzed concentration results for each individual component versus
calibration gas concentrations in the Component Data table.

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4. Adjust timed events if necessary.

Calibration Energy Check Fail

After completing a calibration sequence, the gas chromatograph (GC) performs a
calibration gas energy value check.

If the calculated energy value fails the check, the software automatically runs the
calibration again.

If the second calibration also fails this check, the GC raises a system alarm, Calibration
Energy Value Check Fail.

Recommended actions

1. Ensure the calibration gas bottle is open and not low or empty.

2. Check analyzed concentration results for each individual component versus
calibration gas concentrations in the Component Data table.

3. Adjust timed events if necessary.

Stored Data Integrity Failure

Archived results, event logs, and alarm logs are stored as records in the instrument
database along with a CRC16 checksum. When the data is retrieved, the gas
chromatograph (GC) recomputes the checksum and checks the stored checksum against
the calculated checksum. If they don't match, the GC raises a Stored Data Integrity Failure
alarm.

Recommended actions

1. Reset archives using the dialog under MON2020 → Logs/Reports Menu.

NOTICE

All archived data in the GC will be lost.

2. If this problem recurs, replace the central processing unit (CPU) board.

ROM Checksum Failure

The gas chromatograph (GC) recomputes the firmware checksum at periodic intervals. If
the calculated checksum varies from the original value, the GC raises a ROM Checksum
Failure alarm.

Recommended actions

1. Re-flash the GC controller firmware in Rosemount MON2020: Tools → Upgrade
Firmware.

NOTICE

All archived data in the GC will be lost.

2. If this problem recurs, replace the central processing unit (CPU) board.

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Sample Fluid Unavailable

The stream switching sequence defined in the Custom Logic configuration failed to
successfully execute.

Recommended action

Confirm proper operation of all sample system components and ability to provide
adequate sample flow.

Flame Photometric Detector Board 1 Comm Failure

The gas chromatograph (GC) cannot detect the flame photometric detector (FPD).

Recommended actions

1. Power the GC down completely.

2. Check that all cables are securely connected to the FPD interface module.

3. Power up the GC.

4. If the message appears again, replace the FPD photomultiplier tube (PMT)
module.

4.6.2

Voltage LEDs

A set of LEDs can be found on the back plane.

These LEDs are a quick way to visually inspect the voltage status of some of the gas
chromatograph's (GC's) electrical components.

The following LEDs are associated with the following GC components:

VIN (fuse open)

1 RTN - 24 loop
(Power)

24V regulated (GC
power)

17V (Input for the
preamp)

12V (Input for the
I/O cards0

5V1

3V4

Power ON

Glows red when the fuse has blown or been removed;
otherwise, it is not lit.

Glows when the power supply for the analog outputs is
functioning properly; otherwise it is not lit.

Glows when the GC power is functioning properly;
otherwise, it is not lit.

Glows when the power supply for the preamp is
functioning properly; otherwise, it is not lit.

Glows when thee optional ROC expansion card's power
supply is functioning properly; otherwise, it is not lit.

Glows when the system chip's 5.1 V power supply is
functioning properly; otherwise, it is not lit.

Glows when the 3.4 V power supply for the system chips
is functioning properly; otherwise, it is not lit.

Glows when the GC is on; otherwise, it is not lit.

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4.6.3 Test points

The backplane has a set of test points that allow you to measure the voltage output of the
base in/out (I/O) card.

Figure 4-3: Lower enclosure showing test points on the backplane

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Figure 4-4: Upper enclosure showing test points on the backplane

A. Back plane test points

B. Test points - exploded view

Each test point is labeled with a voltage value that, when measured with a voltmeter,
should give a measurement equal to what is displayed on the label. A reading that does
not match this label may indicate a faulty base I/O card. Try swapping out the suspect card
with a different one, and take another measurement. To get a measurement for a test
point, touch the voltmeter’s negative probe to the DGND test point and touch the
voltmeter’s positive probe to the desired test point.

The test points are associated with the following gas chromatograph (GC) components:

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Table 4-1: Backplane test points and associated GC components

Test Point GC Component

VIN Voltage in N/A

I RTN Isolated return N/A

I 24V (Regulated) Isolated voltage (loop power) 24 V (±2.4 V)

24V (Regulated) GC power 24 V (±2.4 V)

17V5 Preamp (input for the bridge circuit) 17.5 V ±0.5 V

12V Optional I/O cards 12 V ±0.6 V

5V1 System chips 5.1 V ±0.25 V

3V4 System chips 3.4 V ±0.15 V

FVIN Field voltage input 24 V ± 1.5 V

FVGND Field voltage ground 0 V ± 3 V

Tolerances for
DC voltages

The input voltage range for a DC power supply is between 23.5 and 24.5 volts.

The input range for an AC power supply is 90 - 264 volts (auto-ranging).

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4.6.4 Troubleshoot DHCP connectivity issues

1. Ensure that the gas chromatograph (GC) is up and running. If equipped with a
front panel, check the CPU LED on the front panel; a green light means that the
GC is operational. If equipped with a local operator interface (LOI), ensure that
the LOI is communicating with the GC.

2. Check that the SW1 switch is in the On position.

3. Check the following connections:

a) If you are using a Ethernet straight-through cable, ensure that the

personal computer (PC) has an Ethernet network interface card with
auto-MDIX.

b) If your Ethernet network interface card does not support auto-MDIX,

ensure that you are using an Ethernet crossover patch cable.

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c) Check to see if the GC's central processing unit (CPU) board link lights are

on.
See Figure 4-5. The three Ethernet1 LEDs are located on the front

bottom edge of the card. Three Ethernet2 LEDs are just above the
Ethernet1 LEDs. If link lights are off, check your connections.

Figure 4-5: CPU board link lights

A. CPU board
B. Ethernet link lights

4. Do the following to ensure that your network adapter is enabled:

a) Go to Start → Control Panel → Network Connections....

b) Check the status of the Local Area Connection icon. If the status appears

as Disabled, right-click the icon and select Enable from the context
menu.

5. Do the following to try to repair the network connection:

a) Go to Start → Control Panel → Network Connections....

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b) Right-click the Local Area Connection icon and select Repair from the

context menu.

4.6.5 Sample flow balance check

Ensure that the flow panel gauge is properly set. Flow should be as specified on the
Parameter List for the Rosemount 1500XA. To access the list, start MON2020, connect to

the GC and select Logs/Reports → Parameter List....

4.6.6 Carrier flow balance check

Check the flow at the measure vent using a portable electronic flow meter or a mechanical
flow meter.

If your reading is out of range as shown in the MON2020 Logs/Reports → Parameters
List..., do not adjust the pressure regulators; instead, consult your local Emerson
Customer Care representative.

4.6.7

Monitoring the detector(s) and columns temperature

Use MON2020 to monitor the temperature of the detector(s) and columns to determine if
the GC is thermally stable.

When connected to the GC via MON2020, select Hardware → Heaters to access this
function.

When viewing the Heater window, the typical heater configuration is as follows:

The Temperature column on the Heaters window displays the current temperature; the
Current PWM column displays the percentage of power being used to run the heater.

The settings and values shown in the Heaters window and described below, are preset at
the factory and are based on the specific customer application. Do not change these
values unless application engineering or or customer service personnel recommend it or
as part of a factory application requirement.

Figure 4-6: Hardware - Heaters Configuration

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4.6.8 Replace the central processing unit (CPU)

Procedure

1. Save the gas chromatograph (GC) configuration file. In MON2020, go to File →
Save Configuration (to PC).

2. Power down the GC.

3. Open the GC cover.

4. Remove the clear plastic cover that holds the boards in place.

5. Remove the CPU board.

CAUTION

ELECTROSTATIC DISCHARGE (ESD) HANDLING PRECAUTIONS REQUIRED

CPU boards are sensitive electronic devices.

Do not ship or store near strong electrostatic, electromagnetic, or radioactive
fields.

Use an anti-static wrist strap (or ESD wrist strap) when handling the boards.

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6. On the new CPU board, set up switches as shown in the following image:

Figure 4-7: CPU switch settings

A. Turn SW7 ON (toward the dot).
B. Turn SW3 OFF (away from the dot).
C. Turn SW4 OFF (away from the dot).

D. Turn SW6 OFF (away from the dot).

Note

Rosemount 700XA GCs are tagged with CPU board part number 7A00555G02.

7. Install the new CPU board in the card cage.
Ensure the board is seated firmly in place.

8. Place the clear plastic cover back over the boards.

9. Close the GC cover.

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10. Power up the GC and connect to it through MON2020.

11. In MON2020, go to Chromatograph → View/Set Date_Time. Set the date and time
for the GC.

Consult the Rosemount MON2020 Software for Gas Chromatographs Reference

Manual for more information.

12. In MON2020, go to Tools → Cold Boot. Cold boot the GC.
The GC reboots automatically and disconnects from MON2020.

13. Wait for the GC to reboot.

14. Reconnect to the GC using MON2020.

15. In MON2020, go to File → Restore Configuration (to GC). Use the configuration
file you saved in Step 1 or use the last known good configuration.

16. Wait for the heaters to stabilize.

17. Go to Control → Auto Sequence to auto sequence the GC.

4.6.9

Recover the central processing unit (CPU)

Follow this procedure if you have accidentally installed a CPU board with the switch in the
Off position or if unusual things are happening to the analyzer and you suspect a corrupt
CPU.

Important

Do not use a config file saved from a suspect CPU.

Procedure

1. Power down the gas chromatograph (GC).

2. Open the GC cover.

3. Remove the cover from the card cage.

4. Remove the CPU board from the card cage.

5. Ensure the switches on the CPU board are as shown in Figure 4-8.

6. Set the CPU board aside for ten minutes to bleed the contents of the battery backed
random access memory (RAM).

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7. On the CPU board, set up the switches as shown in Figure 4-8.

Figure 4-8: CPU board switch settings

8. Install the CPU board.
Ensure that the board is firmly seated in the card cage.

9. Install the cover on the card cage.

10. Close the GC cover.

11. Power up the GC

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12. Connect to the GC using MON2020.

13. Go to Chromatograph → View/Set Date Time.

14. Set the date and time for the GC. Save your changes.

15. Go to Tools → Cold Boot. Cold boot the GC.
The GC reboots automatically and disconnects from MON2020.

16. Wait for the GC to boot.

17. Connect to the GC using MON2020.

18. Go to File → Restore Configuration (to GC) and restore configuration to the GC.

19. Wait for the heaters to stabilize.

20. In MON2020, go to Control → Auto Sequence to return the GC to normal
operation.

4.7 Checking the GC for leaks

Leak checking is a standard component of any maintenance protocol. See Check the gas

chromatograph (GC) for leaks.

4.7.1

Plugged lines, columns, and valves

If the lines, columns, or valves are plugged, check the gas flow at valve ports.

For a reference, use the flow diagram in the drawing package that shipped with your gas
chromatograph (GC), and remember these points about flow diagrams:

• Port-to-port flow paths are indicated by solid or dashed lines on the valve symbol in the

drawing.

• A dashed line indicates flow direction when the valve is On or energized.

• A solid line indicates flow direction when the valve is Off or not energized.

4.8 Repairing and maintaining the valves

Only minimal valve repair and maintenance is required (e.g., replacing the diaphragms).

4.8.1

Required tools for valve maintenance

The tools required for performing repair and general maintenance on the Rosemount XA
Series valve assemblies are:

• Torque wrench, scaled in foot-pounds

• ½-in. socket for 10-port valves

• 7/16-in. socket for 6-port valves

• ¼-in. open-ended wrench

• 5/16-in. open-ended wrench

• 5/32-in. Allen wrench

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4.8.2 Valve replacement parts

Replacement parts required for each Rosemount XA Series valves consist of the following
parts:

• Diaphragm kit 6-port XA valve (PN 2-4-0710-248)

• Diaphragm kit 10-port XA valve (PN 2-4-0710-171)

Figure 4-9: XA series valves

4.8.3 Overhaul a valve

Note

Rosemount valves have a lifetime warranty. Replacement factory-built XA Series valves are
available. Call your local Emerson Customer Care representative for more information.

If you are overhauling a six-port valve, refer to drawing #CE-22260; If you are overhauling a
ten-port valve, refer to drawing #CE-22300.

Procedure

1. Shut off the carrier and sample gas streams entering the unit.

2. Open the door to the lower enclosure to access the valves.

3. Disconnect tubing and fittings that attach to the valve from other locations.

4. Loosen the attaching bolt on the valve to be replaced or serviced.

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